Densified particulate packaged products

ABSTRACT

A packaged product comprising a container having a container volume; and a quantity of densified particulate products having a tapped bulk density ranging from 0.08 g/cc to 0.4 g/cc disposed within the container, wherein the quantity of densified particulate products occupies more than 85% of the container volume is provided. A process for producing the packaged product includes densifying a quantity of densifiable particulate products prior to forming a closing seal in its container. In one embodiment, vibrational forces are applied to a temporary container as it is being removed from a shipping container.

RELATED APPLICATIONS

This claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application Ser. No. 61/220,760 filed on Jun. 26, 2010, which is hereby incorporated by reference in its entirety.

BACKGROUND

Conventional packaging methods for cereal, snack and dry mix products include use of vertical form, fill and seal machines. This method, referred to as a “bag-in-a-box” (B-I-B) method, can operate at lines speeds of about 100 to 200 units per minute. The method generally begins with forming and filling a bag and thereafter, inserting the bag into a partially assembled carton (open ended) box. The bag forming and filling operation comprises wrapping a ribbon of flexible packaging film around a forming and filling horn. The film is then sealed longitudinally to create a tube. One end of the tube advances through a pair of heated sealing jaws, which engage the tube, form a transverse (lower) seal, and separate the newly formed cylinder of film from the preceding unit, i.e., a bag with one open end. A quantity of material, such as RTE cereal, is then added through the inside of the forming and filling horn into the cylinder. The product free falls from a hopper into the cylinder without interruption.

Thereafter, as the tube is advanced, sealing jaws engage the cylinder, form a transverse (upper) seal, and separate the newly formed closed bag from the sealed end of the following open bag, which has simultaneously received its first lower seal (to form a cylinder). Therefore, the final bag has three seams, including one extending longitudinally along a back surface and two extending transversely along upper and lower ends of the bag.

The carton is assembled separately with top (or bottom) flaps retained in an open position until the filled bag is added to the box. The carton flaps are thereafter glued and folded, to form the finished article. Since the bag is filled prior to being placed in the carton, additional functional void (beyond the void space within the bag itself) must be allowed, in order for the filled bag to fit within the carton. The end result after shipping, is a consumer product with a large amount of headspace, i.e., at least 20% up to 40% of the package volume, upon reaching the consumer.

SUMMARY

The inventors have discovered a need for improved particulate packaged products and methods for making same, which provide increased benefits to the consumer, manufacturer and the environment. In one embodiment, a packaged product comprising a container having a container volume; and a quantity of densified particulate products having a tapped bulk density ranging from 0.08 g/cc to 0.4 g/cc disposed within the container, wherein the quantity of densified particulate products occupies more than 85%, such as up to 90% or up to 95% or more, of the container volume, is disclosed. In one embodiment, a difference in percentage fullness of the container upon fabrication to percentage fullness after shipping is no more than five (5) %.

In one embodiment, the container volume is reduced as compared to the volume of a container having an identical quantity of non-densified packaged products disposed therein, such as between about 3.6% up to 25%, greater than 3.6% and less than 14.8%, such as by at least eight (8) %. Use of a bag having a volume which is reduced in size, i.e., a smaller-sized bag, to contain the same weight of cereal allows for containment of the bag in a carton similarly reduced in volume, i.e., a smaller-sized carton, thereby saving in amount of packaging material used.

For example, a typical medium-sized box of RTE cereal contains about 252 g of RTE cereal, although a specific fill weight may vary by up to a few grams. A conventional bag for containing this quantity of RTE cereal may have a volume of about 3000 cc, which includes headspace volume. In contrast, embodiments of the present invention provide for bags having a volume which is reduced in size for a given quantity of particulate products. In one embodiment, the bag volume is reduced in size by up to 450 cc in volume. In one embodiment, the bag volume is reduced in size by about 300 cc in volume for 252 g of RTE cereal, representing a 10% reduction in bag volume as compared to the volume of a conventional bag. In this embodiment, the container can have an aspect ratio of width to depth of about 3.5 to 1 and a height no more than about ten (10) inches (in) (25.4 cm).

Embodiments of the present invention provide for a packaged product, wherein the container is a sealed container having a first transverse seal with a lower edge and the quantity of densified particulate products form a bed having a top surface, and a distance between the lower edge of the first transverse seal and the top surface of the bed is no more than three (3) cm, such as no more than 1.25 cm.

In one embodiment, the packaged product is a flexible bag made from any suitable material, such as polyethylene or polyester. In one embodiment, the flexible bag is a stand-alone container that is wider at the bottom and/or flat bottomed, and which may optionally be metalized. In one embodiment, a carton surrounds the flexible bag. The carton may have a substantially rectangular shape, a substantially cubular shape, or a substantially cylindrical shape. In one embodiment, the carton has a gable top.

In one embodiment, the quantity of densified particulate products is a quantity of densified particulate food products, such as ready-to-eat cereal (RTE) pieces having a variety of shapes, such as o-rings, spheres, rectangles, flakes, squares and any combination thereof. In other embodiments, the quantity of particulate food products is selected from uncooked pasta, dehydrated potatoes, and snack products, wherein the snack products include bugle-shaped products, loosely packaged crackers (vs. a stacked array), potato chips, and the like.

Embodiments of the invention further comprise a process comprising wrapping a film around a mandrel; forming at least one transverse seam in the film to form a tube; sealing the tube on at least one end to form a bag; filling the bag with a quantity of densifiable particulate products (such as a RTE cereal product) having an initial bulk density between 0.08 g/cc and 0.3 g/cc; and vibrating the mandrel to produce a quantity of particulate products having a final bulk density at least 8% greater than the initial bulk density of the quantity of particulate products.

In one embodiment, the vibrating step comprises vibrating the mandrel and/or bag intermittently or continuously in one or more locations of the process at a frequency (such as about five (5) to 50 Hz or about 17 to 19 Hz), amplitude (such as less than about 2.5 cm or less than about 0.5 cm) and duration (such as less than about 15 seconds) sufficient to densify the quantity of densifiable particulate products. In one embodiment, one of the one or more locations occurs where the mandrel is being removed from the bag, wherein vibrational forces are applied to the upper portion of the mandrel. In one embodiment, vibration is applied in more than one direction or vector, such as with an up-and-down as well as with a back-and-forth and/or a side-to-side vibration.

In one embodiment, the process further comprises forming at least two transverse seams in the film, and further may comprise removing the mandrel from the bag (such as at a rate of about three (3) to seven (7) cm/sec); and forming a closing seal in the bag.

In one embodiment, the process further comprises wrapping a carton around the bag to form a carton prior to forming the closing seal in the bag, and may further comprise filling the bag with the quantity of particulate products prior to removing the bag and carton from the mandrel. In a particular embodiment, the initial bulk density is between about 0.08 and 0.25 g/cc. In one embodiment, the process further comprises wrapping the film around a lower portion of the mandrel and the filling step further comprises filling an upper portion of the mandrel with the quantity of particulate products; and transferring the particulate products from the upper portion of the mandrel to the lower portion of the mandrel, such as by tipping the mandrel from a substantially horizontal position to a substantially vertical position. In one embodiment, protrusions in the mandrel create drag for the quantity of particulate products during transfer to facilitate densification.

Embodiments of the invention further comprise a process which includes densifying a quantity of densifiable particulate products (such as a RTE cereal product), wherein the densifying comprises transferring the densifiable particulate products from a temporary container to a sealable container formed around a portion of the temporary container; and vibrating the temporary container, the sealable container or a combination thereof, wherein the quantity of densifiable particulate products are densified prior to forming a closing seal in the sealable container.

In one embodiment, the quantity of densifiable particulate products is densified while the temporary container is being removed from the sealable container. In one embodiment, the sealable container is a bag, such as a standalone bag, or a package comprising a bag surrounded by a carton. In a particular embodiment, the quantity of particulate products is about 252 g of a RTE cereal product.

Embodiments of the present invention further include various products made according to the processes discussed herein. In most embodiments, such products include a container comprising a carton having an inner bag to contain the densified particulate products. However, the container may comprise a stand-alone bag which does not have an exterior carton. Such bags may be employed in a wide variety of packaged food articles such as potato chip bags, corn chip bags, and the like.

The novel packaged products described herein utilize all “corners” of a container, including the “corners” which would otherwise be included in the functional void of conventional packaged products. The novel packaged products further utilize much of the remaining portion of what would otherwise be headspace, which may further improve the shelf life of the novel food products contained therein.

Additionally, and in contrast to packaged products produced by conventional B-I-B methods, with the dramatic reduction in headspace, the novel packaged products described herein require a smaller container (less volume and less material) for a given volume of cereal. Stated another way, a greater quantity of product can be added for a container of a given shape or volume. Also, since the quantity of packaged food product per volume is increased, additional efficiencies and cost saving can be obtained during transportation associated with distribution and sale. Typically for these types of packaged consumer food products, the volume of a truck is the limiting factor, not the weight of the product carried by the truck. By reducing the packaging volume, more units of packaged food products can be transported per individual truck leading to reductions in transportation costs.

The novel methods described herein can also be practiced at higher packaging rates per minute than conventional DP methods, with speeds comparable to or exceeding current bag-in-a-box methods. In embodiments which utilize both a flexible bag surrounded by an outer carton, there is also no need to allow for additional functional void or to adjust content volume in order to avoid bulging of the carton, as with current bag-in-a-box methods.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic drawing of a densified food product in a container in an embodiment of the present invention.

FIG. 2 is a schematic drawing of a densified food product in an alternative container in an embodiment of the present invention.

FIG. 3A is a schematic drawing of a densified food product in a six-sided container as compared with a non-densified food product in a conventional six-sided container in an embodiment of the present invention.

FIG. 3B is a schematic drawing of a packing crate containing a plurality of densified packaged products as compared with a packing crate containing a plurality of non-densified packaged products in an embodiment of the present invention.

FIG. 4 is a schematic drawing of a densified food product in an alternative six-sided container in an embodiment of the present invention.

FIG. 5 is a schematic drawing of a densified food product in another alternative container in an embodiment of the present invention.

FIG. 6 is a schematic drawing of a densified food product in yet another alternative six-sided container in an embodiment of the present invention.

FIG. 7 is a schematic drawing of a densified food product in yet another alternative 10-sided container in an embodiment of the present invention.

FIG. 8 is a schematic drawing of a densified food product in a container having a gable top in an embodiment of the present invention.

FIG. 9 is a schematic drawing of a densified food product in a substantially round container in an embodiment of the present invention.

FIG. 10A is a simplified schematic diagram of a process for making a densified particulate packaged food product showing a mandrel near the beginning of the process in location “A” in an embodiment of the present invention.

FIG. 10B is a perspective view of an alternative mandrel in an embodiment of the present invention.

FIG. 11A is a simplified schematic diagram of the process of FIG. 10A showing the mandrels positioned at three sequential points in time in locations “B”, “C”, and “D”, in embodiments of the present invention.

FIG. 11B is a perspective view of a mandrel and film after passing through location “B” (shown in FIG. 11A) in an embodiment of the present invention.

FIG. 12 is a simplified schematic diagram of an alternative process for making a densified particulate packaged food product using a single source of film in an embodiment of the present invention.

FIG. 13 is a close-up of a mandrel at a filling station in an embodiment of the present invention.

FIG. 14 is a simplified schematic diagram showing cam followers on a back surface of the mandrel in an embodiment of the present invention.

FIG. 15 is a simplified schematic diagram of the process of FIG. 10A showing the mandrel positioned at sequential points in time in locations “E” and “F” in embodiments of the present invention.

FIG. 16 is a simplified schematic diagram showing an end view of the mandrel in location “D” (shown in FIG. 11A) in embodiments of the present invention.

FIG. 17 is a simplified schematic diagram of the process of FIG. 10A showing the mandrel positioned at sequential points in time in location “G”, in embodiments of the present invention.

FIG. 18 is a simplified schematic diagram of the process of FIG. 10A showing the mandrel in location “H”, in an embodiment of the present invention.

FIG. 19 is a simplified flow diagram of a method for making a densified particulate packaged food product in an embodiment of the present invention.

FIG. 20 is a simplified flow diagram of a method for making a densified particulate packaged food product in an embodiment of the present invention

FIG. 21 is a simplified sketch of a test stand in an embodiment of the present invention.

DETAILED DESCRIPTION

In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized. It is also to be understood that structural, procedural and system changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

When used in the figures, the same numerals designate the same or similar components. As such, although each numbered component is discussed herein, not every numbered component shown again in a subsequent figure is necessarily discussed further with the subsequent figure description.

When the terms “up,” “down”, “top”, “bottom”, “first”, “second”, and “edge” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawings as it would appear to a person viewing the drawings and are utilized only to facilitate describing embodiments of the invention. As such, these terms are not intended to be limiting in nature. Therefore, what is at one point in the process is described herein as a “bottom” may become a “top” at a later point in time. For example, in one embodiment, the first seal is, at the time it is formed, a bottom seal of a container. In this embodiment, the second seal is, at the time it is formed, a bottom seal. However, in use, such a container may be intended to be rotated to be right-side-up in relation to printing on an outside carton, for example, such that the first seal becomes the top seal and the second seal becomes the bottom seal. In such embodiments, therefore, the containers are being filled with food product during the densification process through the “bottom” (such that the container is upside-down as compared to the orientation of the final product), although the invention is not so limited.

Various terms used throughout the description are defined first, followed by a discussion of various densified particulate packaged food product embodiments. The process for making the densified particulate packaged food products are described next, followed by a brief conclusion highlighting some of the advantages of the various embodiments.

DEFINITIONS

The term “container” as used herein refers to any type of vessel that is capable of holding a quantity of particulate products, either temporarily or permanently. Generally, as used herein, the term “bag” or “liner” (defined below) is intended to refer to a flexible container, which includes any type of flexible stand-alone container made of any suitable material, such as one or more layers of paper, and the like. In contrast, the term “carton” is intended to refer to a more rigid container, such as the cardboard containers used to package RTE cereal products. Cartons can further be lined (with substrates containing polyethylene, foil, polypropylene, metalized materials, and the like), coated with polyethylene, polypropylene, paraffin, and the like) or unlined and/or uncoated. The carton can also include exterior layers, such as a clay layer adapted to receive color or graphics applied (e.g., printed) that the consumer will see. The term “carton” can also include containers such as canisters that are fabricated to include one or more rounded corners or edges. A mandrel may further be a container.

The term “bulk density” as used herein, refers to the mass or dry weight of a quantity of particles or particulates (granules and other “divided” solids,” such as dry food particulate products) divided by the total volume they occupy (mass/volume). Therefore, bulk density is not an intrinsic property of the particles, as it is changeable when the particles are subjected to movement from an external source. The volume measurement is a combination of the particle volume (which includes the internal pore volume of a particle) and the inter-particle void volume. The bulk density of the quantity of particles is inversely related to the porosity of the quantity of particles.

The term “low bulk density” as used herein, refers to a quantity of pieces or particles (which are not “soft” or “squishy”, e.g., not compressible without fracture) having a tapped or final bulk density of less than 0.4 g/cc, but not less than 0.08 g/cc, which is considered an “ultra-low bulk density” particle. Examples of low bulk density particles include, but are not limited to, low bulk density divided solids, such as various dry foods, including RTE cereal products, uncooked pasta pieces, dehydrated potatoes, snack foods (e.g., potato chips, corn chips, bugle-shaped products, and the like). Products such as rice, granola, uncooked oats, coffee beans, ground coffee, fine powders, and the like, are not encompassed in this definition as they have a freely settled density well above 0.3 g/c, such as greater than 0.5 g/cc. Products such as popped popcorn are also not encompassed in this definition as these products are considered “ultra-low bulk density” particles, having a freely settled density generally less than 0.08 g/cc.

The term “freely settled density” or “loose density” as used herein refers to the bulk density of a quantity of particles after being added by simple addition to a stationary or non-moving container without purposeful densification, such as without applied agitation. The “loose density” is dependent on a number of factors, including the rate at which the quantity of particles is being added. A maximum or theoretical loose density is achieved when the quantity of particles is added to the container at a rate sufficiently slow so as to eliminate or substantially minimize the effect of newly added particles to existing particles. In practice, however, particles may be added to a container at a slightly higher rate, in order to maximize manufacturing efficiency. Therefore, the term “loose density” as used herein is not intended to refer to the theoretical loose density, but to something lower than the theoretical loose density. The “loose density” achieved during a typical manufacturing operation can differ from the theoretical loose density by up to ±5% or more, possibly as high as ten (10) %.

The term “densifiable” as used herein refers to a low bulk density particle (as defined above) which, when present in a given volume, has a void volume between adjacent particles which is reducible by at least 8% (i.e., the initial or freely settled void volume and final or tapped or packed void volume have a delta (A) of at least 8%) and without compaction or substantial reduction in the size of the particles (e.g., breakage). Particles considered densifiable do not include particles which are granular or powder-sized or smaller, such as “fines,” as the term is understood in the art, although it is understood that the packaged products described herein may contain a quantifiable amount of fines. As such, densifiable particles are likely at least about one (1) cm in size in at least one dimension. Examples of low bulk density particles include, but are not limited to, low bulk density divided solids, such as various dry foods, including RTE cereal products, uncooked pasta pieces, dehydrated potatoes, especially in sliced form, snack foods (e.g., potato chips, corn chips, bugle-shaped products, and the like).

The term “packed density” or “tapped density” as used herein refers to a “final bulk density,” i.e., the bulk density of a quantity of particles after undergoing a densification or non-compressive compaction process, such as vibration of the container in which the quantity of particles is contained and/or will be contained. It is to be understood that the packed density described herein is achieved without use of a vacuum or vacuum process, i.e., with a non-vacuum process. The packed density is not necessarily the maximum bulk density of a given quantity of particles, but is necessarily higher than the original or loose density of the particulate products by at least 8%. The packed density is further dependent on a number of factors, including the quantity, size, irregularity and shape of the quantity of particles. In order to minimize breakage, the packed density of frangible particulate products, may be less than that of non-frangible particulate products.

The term “densified” as used herein refers to the end result of a non-compressive densification process in which a quantity of “densifiable” particles have been compacted sufficiently, such as with vibration, to reduce the initial void volume by at least 6% so as to achieve a “packed density” as defined herein. This is in contrast to densification achieved by compressing “soft” or “squishy” particles by any means, such as with pressure applied to the container by compression. Examples of soft particles include popped popcorn, popped caramel corn, soft (or undried) marshmallows, French fries, cigars, cigarettes, and the like, which, in contrast to non-soft particles, would also experience a reduction in the internal pore volume of each particle after undergoing a densification or compression process.

The term “frangible” as used herein refers to particulate products which are fragile or breakable into more than one piece upon being dropped or upon application of minimal pressure, such as less than about 14.7 psi, possibly as low as seven (7) psi. A “frangible” particulate product is to be distinguished from a “soft” particulate product (e.g., French fries, cigars, and the like) which are compressible or bendable into another shape, but would not break into more than one piece with application of minimal pressure. For example, potato chips and RTE cereal flakes (e.g., corn flakes) are frangible.

The term “liner” or “bag” as used herein refers to a flexible material having at least one layer. The bag may also be a laminate material or a co-extrusion. The bag may be made from any suitable material in one or more layers, such as polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), and polylactic acid (PLA). The bag may further comprise an oxygen barrier layer and/or a moisture barrier layer comprising a metalized polymeric composite. The flexible material may further be a paper product, such as a glassine, waxed paper bag, and the like.

Conventional Double Packaging Filling Method

Double packaging (DP) machines were commonly used prior to development of the bag-in-a-box (B-I-B) method (discussed in Background Section). However, double packaging technology is generally limited to line speeds of only about 60 to 90 units per minute.

With the DP method, both the bag and surrounding carton are formed around the same stationary mandrel. The interim bag has three seams, including two extending longitudinally along opposing sides, and one extending transversely along one end, with the opposing end remaining open. The resulting double package, comprising a bag surrounded by a carton, is then taken off the mandrel and advanced to a separate filling station where it is filled with a quantity of cereal through its open end.

To reduce the possibility of bulging in the final packaged product, the product volume is kept at a relatively low level. The filled unit is then advanced to another station for sealing of the open end with a transverse seal. Thereafter, the carton flaps are applied with sealant, and folded to close the carton.

Although much slower than the B-I-B method discussed above, the DP method has a closer tolerance between the bag and the carton, especially in the corners. As such, the DP method produces a product which is considered to be utilizing the “corners” of its bag, although it is understood that only two such “corners” are being utilized. The other two “corners” are part of the substantial headspace, which accounts for at least 20% up to 40% of the package volume, upon reaching the consumer.

Densified Particulate Packaged Product Embodiments

The novel densified particulate packaged products (hereinafter “densified packaged products”) described herein, utilize all “corners” of a container, including the “corners” which would otherwise be included in the headspace of conventional packaged products. The novel densified packaged products further utilize most of the remaining portion of what would otherwise be headspace, thus improving the shelf life of the densified food products contained therein and providing a more environmentally friendly package, by reducing the amount of packaging material needed to contain a given weight of product. Additionally, and in contrast to packaged products produced by conventional methods (such as the conventional DP method), with the reduction in headspace, the densified packaged products described herein require a smaller container (less volume and less material) for a given weight of densified product, such as RTE cereal products or snack products. Stated another way, more weight or quantity of product can be added for a container of a given shape or volume.

Embodiments of the invention comprise a densified packaged product comprising a container having a container volume; and a quantity of densified products disposed within the container, wherein the quantity of densified products occupies more than 85% of the container volume. In one embodiment, the densified products are low bulk density divided solids, such as dry food products, having a tapped bulk density less than about 0.4 g/cc, but not lower than 0.08 g/cc. In one embodiment, the quantity of densified products occupies at least 90% of the container volume or at least 95% of the container volume. As a result, the container volume (and, therefore the container itself) is reduced in size in embodiments of the present invention, as compared to a container volume of a container having an identical quantity of non-densified products disposed therein.

In one embodiment, the densified packaged product has more than one compartment. In one embodiment, the quantity of densified products is one or more different types, shapes and/or sizes of densified products, e.g. cereal flakes and cereal biscuits and/or clusters admixed to form a composite blend.

Conventional densifiable packaged products, such as conventional densifiable packaged food products, including cereal, snack and dehydrated packaged products, are not currently intentionally densified prior to filling and sealing, but merely allowed to settle naturally during the manufacturing and shipping processes. Conventional densifiable packaged products, therefore, require an initially (i.e., at time of filling) oversized bag, and, if including a protective outer carton, within an oversized carton to accommodate the oversized bag with substantial headspace (volume of empty space between the top of the contents and bottom edge of the bag seal) present by the time the product reaches market, and is ultimately opened by the consumer.

Such bag headspace typically occupies a volume greater than 20% up to about 40% of the bag interior, as well as a like percentage or greater “spare” headspace volume of the carton interior, depending on the size of the bag and surrounding carton, if present. For example, in a particular carton for a puffed RTE cereal package employing a carton having dimensions of 10.25 in (26.04 cm) (height) by 7.625 in (19.37 cm) in (width) and two (2) in (5.08 cc) (depth), the volume is about 156 in³ (˜2550 cc). Such a conventional carton can have 30 to 65 in³ (˜510 cc to 1025 cc) of headspace above the bed of the cereal disposed within the bag upon reaching the consumer, with the bag actually containing the RTE cereal having a comparable headspace. Due to such settling and the large headspace created by such settling, upon opening by the consumer, the consumer can erroneously conclude that the bag was underweighted with contents, thus leading to consumer complaints to and against the manufacturer.

In contrast, the novel densifiable packaged products described herein are densified prior to closure (by applying a final closure seal), thus allowing for reductions in container headspace, including, for example, in both a bag and, if present, a protective outer carton surrounding the bag. As a result, the headspace in the various embodiments described herein, can be reduced by at least five (5) % up to 25% relative to conventional equivalent articles which are not (intentionally) densified prior to closure, but which have undergone densification only through unintentional means, i.e., naturally, during the manufacturing and shipping processes. In the above embodiment, the reduction in headspace will be at least five (5) % of the minimum headspace volume (0.05×30 in³=1.5 in³) up to as great as 25% of the maximum volume (0.25×65 in3=16.25 in³). In one embodiment, a container is provided having a volume of 154 in³ (2524 cm³) and a headspace less than about 250 cm³. In other embodiments, the headspace is less than 200 cm³ and can be, in some embodiments, no more 125 cm³. This reduction in headspace can be achieved either by adding more quantity of RTE cereal to the container or by reducing or sizing a smaller container to package an equal quantity of cereal.

Reduction in headspace provides increased satisfaction to the consumer, who, upon opening and viewing the packaged product, views a container (e.g., bag within a protective outer carton) which is suitably proportioned in size to its contents. In other words, the consumer's expectations of opening and viewing a substantially full container, is met. Reduction in headspace also improves shelf-life and further allows for a reduction in the amount of packaging material required to package a given amount of a densifiable food product. Reduced packaging requirements provide long-term environmental benefits in terms of fewer raw materials needed and less waste. Additionally, since package size is reduced, a larger amount of densified product can be stored in a given package volume. Smaller packages also provide numerous benefits during shipping in terms of reduced costs, reduced fuel requirements, and, likely, less product breakage.

Reduction of the headspace also means substantial reduction in the vertical distance between the top of the cereal bed and the bottom of the top seal as compared with conventional packaged products, which have at least about five (5) cm to ten (10) cm, depending on the shape and size of the outside carton. In contrast, in most embodiments described herein, this distance, although variable, as a cereal bed is not a straight line, is likely less than three (3) cm, such as less than 2.54 cm.

FIG. 1 shows one embodiment of a densified packaged product 10 of the present invention comprising a quantity of densified particulate products 12 in a container 14 having an upper or top transverse seal (hereinafter “top seal”) 16 with a bottom edge 17. FIG. 1 is intended to be representative of a flexible container of any type and is not drawn to scale. As such, FIG. 1 does not necessarily represent the actual tapped density of the quantity of densified particulate products 12 contained therein, nor the actual proportion of the various components. Also, in certain variations in which the articles are bottom filled, the “top” or open end can actually be the bottom end, as seen by the consumer in the finished article.

In this embodiment, the quantity of densified particulate products 12 forms a bed 18 having a top surface 23. In one embodiment, the top seal 16 has a height of about one (1) cm to about two (2) cm. In such an embodiment, a distance 19 from the top surface 23 of the bed 18 to the bottom edge 17 of the top seal 16 is no more than about 2.54 cm to about 7.62 cm. In other embodiments, distance 19 (which is variable as shown) is less than about 2.54 cm, such as about 1.25 cm. Moreover, this vertical distance will vary only modestly (2-5%) between final sealing and delivery to the consumer. This is in contrast to current packages wherein the vertical distance can double between fabrication and opening by the consumer.

Distance 19 will also vary depending on the shape, size and type of container 14. In one embodiment, the container 14 has a height (including the top seal 16) of about 10.25 in (26 cm), a depth of about 2 in (5 cm) and a width of about 7.6 in (19.4 cm), and distance 19 is no more than five (5) cm. This is in contrast to a conventional packaged product having the same dimensions and containing particulate products which are not “pre-densified,” in which distance 19 would be at least eight (8) cm up to ten (10) cm or more (See, for example, FIG. 3A).

In the embodiment shown in FIG. 1, the container 14 has a substantially rectangular shape with an angled top portion, creating a gable-shaped top. In one embodiment, the container 14 in FIG. 1 is a stand-alone container. In other embodiments, the container 14 is comparable to conventional bags inside RTE cereal cartons. (See, for example, U.S. Pat. Nos. 5,379,886 and 7,021,525, both of which are hereby incorporated by reference in their entirety. Of course, such conventional bags will be larger for the same weight of food product contained therein, as compared to the various novel containers described herein). In one embodiment, the container 14 shown in FIG. 1 has a height (including the top seal 16) of less than about nine (9) in (22.3 cm), a maximum depth of less than about two (2) in (5.1 cm), a width of less than about 7.5 in (19.1 cm), and a distance 19 of no more than about 0.5 in (1.25 cm).

FIG. 2 shows one embodiment of a densified packaged product 20 of the present invention, which includes a bag 14 contained within an outer container (such as a carton) 22 having foldable flaps 24. Disposed within the bag 14 is a densified cereal product 12 (such as puffed, ring-shaped oat-based cereal, marketed under the Cheerios® brand). In this view, the bag 14 has been pulled partially out of the container 22 for viewing. (As with the embodiment shown in FIG. 1, distance 19 from the top surface 23 of the bed 18 to the bottom edge 17 of the top seal 16 is no more than about one (1) in (2.54 cm) to about 1.5 in (3.81 cm)).

The container 22 can be any suitable shape and size, but will generally be smaller in volume (and thus require less packaging material) than a conventional container containing the same weight of particulate food product. In the embodiment shown in FIG. 2, the container 22 has a substantially rectangular slab shape. In this embodiment, the container 22 is oriented in a portrait (versus a landscape) configuration, although the invention is not so limited. The container 22 may be constructed of any suitable materials. In one embodiment, the container 22 is constructed from the same type of materials used in conventional RTE cereal cartons, such as from a paperboard material which may be lined, coated, or unlined, as defined herein.

In one embodiment, both the conventional container 31 and the novel container 30 described herein have the same relatively high aspect ratio (width:depth), such as about 7.5:2 or 3.5:1, which is characteristic of a slab-shaped box. However, for the same aspect ratio, the ratio of the height of the conventional container 31 to the height of the novel container is expected to be about 11:8. In one embodiment, containers having a higher width to depth aspect ratio, such as greater than about 3.5:1 are combined with densifiable products to produce novel densified packaged products, as defined herein. In other embodiments, the height may remain the same, but the novel products herein may have a reduced depth. In one embodiment, the width:depth aspect ratio and the depth value remain constant (relative to current commercial products) but their height is reduced to provide cartons of reduced volumes.

It is expected that for a given weight of food product, the containers described herein, such as container 30 shown in FIG. 3A, will generally be at least five (5) % up to 25% (including any range there between) smaller in volume than a conventional container 31 (having the same width:depth ratio). In one embodiment, container 30 has a height about 20% to about 30% less than the conventional container 31 for the same weight of food product. In one embodiment, container 30 has a height (including the top seal 16) of about nine (9) in (22.3 cm), a depth about two (2) in (5.1 cm), a width of about 7.5 in (19.1 cm). In this embodiment, the distance 19 of the inner bag 38 is no more than about 1.25 cm. This is in contrast to the conventional container 30 (of comparable width and depth), which has a height of at least about 11.25 in (28.6 cm) and a distance 39 of at least 2.5 cm up to 9 cm or more.

In one embodiment, about 300 g to about 400 g of densified food product 32 is contained with the smaller novel container 30. In a particular embodiment, approximately 347 g of densified food product 32 is contained within a novel container 30 having a height of only about nine (9) in (22.3 cm), which is in contrast to a conventional container 31 containing the same weight of non-densified food product 34, which would require a height of at least about 11.25 in (28.6 cm).

In some embodiments, it may be desirable to retain a conventional package size. In such embodiments, use of the novel methods described herein allows at least five (5) % up to 25% (including any range there between) more food product to be packaged in a given package size.

According to known international standards, a single serving of most cereals (other than dense cereals, such as granola, muselix, or fruit and nut bran cereals) is considered to be about 30 g (weight), which corresponds to a volume of from about 0.2 to 0.3 Liters (L) (about 0.75 to 1.25 cups). In one embodiment, container 30 of the present invention has a volume of about 243 in³, a height of about 10.63 in (27 cm), a depth of about three (3) in (7.62 cm) and a width of about 7.63 in (19.4 cm), and holds about 13 single servings or about 390 grams of densified food product 32. In one embodiment, the container 30 holds about 390 g of densified food product 32. This is in contrast to a conventional container 31, also shown in FIG. 3A, which, for the same weight of non-densified cereal product (390 g) 34, requires a container 31 having a larger volume of 270 in³, with a height of at least about 11.75 in (29.8 cm), and a similar width and depth. Thus, in some embodiments a full inch (2.54 cm) can be taken off the height of the containers 30 discussed herein, while packaging the same quantity of RTE cereal.

The densified packaged products herein will further undergo significantly less additional distribution-related settling or densification after addition of the closing seal in the container as compared with conventional packaged products. In other words, due to the novel densification process described herein, the densified packaged products described herein will experience minimal settling during shipping. For example, a container which is filled to 85% of capacity (with tapped densification) upon fabrication will likely still be filled to at least 80% of its capacity (volume) after shipping, i.e., upon reaching the consumer. In one embodiment, such a container is still filled up to 83% of its capacity (volume) upon reaching the consumer.

In other embodiments, the container is filled to more than 85% of capacity (volume) during manufacturing, such as up to 90%, or 95% or above, such as up to 98%, and experiences no more than two (2) % or 3% or 4% or 5% up to less than 10% further densification after addition of the closing seal to the container, leading to a comparable reduction in capacity (volume). This is in contrast to conventional packaged food products, which experience a volume reduction of at least about 10% up to 40% after addition of the closing seal in the container. (Therefore, although such conventional food products may be filled to 90% capacity (volume) prior to the final seal being added, they are filled only to about 75% or less upon reaching the consumer. As a result, the densified packaged food products described herein have an improved ratio of percent (%) package fullness before shipping (initial bulk density) as compared to after shipping (final bulk density), such as 85:80.

In most embodiments, it is further expected that the ratio of the weight of the densified product to the package volume (w/v) will be in a novel range, midway between conventional packaged products containing low bulk density products (e.g., puffed RTE cereal products) and conventional packaged products containing high bulk density products (e.g., granola products). In one embodiment, the novel densified packaged products provided herein have a w/v percentage greater than 3.6%, and less than 14.8%. In one embodiment, the w/v is five (5) % to eight (8) % or about six (6) % to about seven (7) %.

Densified products may include densified food products, as defined herein, having any type of simple or complex shape or mixtures of shapes (i.e., comprised of, for example, two or more distinctly shaped cereal components). This includes regular geometric shapes (e.g., squares, rounds, triangles, hexagonals, tubes, biscuits, puffed rings or “O's”, and so forth) and irregular shapes, which can be patterned (e.g., flakes, figurines, animals, trees, holiday shapes, stars, pillows, twists, wagon wheels, letters, numbers, etc.) or unpatterned, such as a nugget shape. In one embodiment, the densified food products include known RTE cereals, including, but not limited to, any type of Cheerios® (e.g., regular Cheerios®, Apple Cinnamon Cheerios®, Honey Nut Cheerios®), any type of Chex® (e.g., Honey Nut Chex®, Wheat Chex®, Rice Chex®, Corn Chex®, Bran Chex®), Cocoa Puffs®, Cinnamon Toast Crunch®, Oatmeal Raisin Crisp®, Wheaties®, Total®, Lucky Charms®, Trix®, Country Corn Flakes®, Golden Grahams®, generic substitutes for these and other RTE cereal products, various combinations of one or more cereal types, and so forth. Densified food products may further include uncooked pasta, dehydrated potatoes, potato chips, salty snacks, and the like, of any shape and size. The present randomly aligned quantity of loose densified products are, of course, to be distinguished from ordered stacked arrays of regular shaped products, such as fabricated potato products prepared from cooked potato dough typically packaged in the form of a stacked array or stacked square crackers.

In one embodiment, the densified food product is a puffed RTE cereal product, such as a substantially o-shaped particle (See FIGS. 1 and 2) or a substantially spherically-shaped particle, and the container is at least six (6) % or at least seven (7) % or at least eight (8) % smaller than a conventional container containing the same weight of food product. In one embodiment, the densified food product is a flaked RTE cereal product or a “sprout” RTE cereal product, i.e., a generally rectangular biscuit (See, for example, FIG. 3A). In the embodiment shown in FIG. 3A, the container 30 is at least 15% small than a conventional container 31 containing the same type and weight of food product. In other embodiments, the container 30 is at least five (5) % to ten (10) % or ten (10) % to 25%, or five (5) % to 20% (including any range there between) smaller than a conventional container 31 containing the same type and weight of food product.

In one embodiment, the invention comprises a case 35 containing a plurality or multiplicity of containers 30, such as the 12 containers 30 shown in FIG. 3B in a 2×6 array, although the invention is not so limited. In one embodiment, each container 30 has a height of about nine (9) in (22.3 cm), a depth of about two (2) in (5.1 cm) and a width of about 7.5 in (19.1 cm), as described above, such that each case 35 has a height of about 9.5 in (24.13 cm), a width of about 15.5 in (39.37 cm) and a length of about 19 in (48.26 cm). This is in contrast to a convention case 37, also shown in FIG. 3B, which, for the same number of conventional containers 31, requires a case 37 having a height of about 12 in (30.48 cm), and an equivalent width and length.

In other embodiments, the case 35 may hold more containers 30, such as 16 or more, or fewer containers, such as six (6), such as in a 1×6 array or in a 2×6 array. With the reduction in volume of at least about 5% up to 25% for each container 30, the overall volume of the case 35 is reduced by at least about 5% up to 25%. This is in contrast to a conventional case 37, also shown in FIG. 3B, which, for the same number of conventional containers 31, requires a larger case 37.

Cases 35 are generally stacked in rows one atop another for shipping, such as on pallets, as is known in the art. In one embodiment, about two (2) to eight (8) cases 35 are stacked in a row, although the invention is not so limited. Any number of rows cases 35 may be stacked together (e.g., 3-8). With use of the novel densification process described herein, the reduction in volume (and packaging material) for each individual package, combined with the reduction in volume (and packaging material) for each case 35, leads to a reduction in volume (and packaging material) for each pallet being shipped, such as about five (5) % to about 25%. Therefore, while the height difference per case may be small in some embodiments, such a difference can be sufficient to include an additional entire row on each pallet. An extra row of cases per pallet can increase the total number of cartons on a semi-trailer by up to 10% or higher, such as up to about 30%. By transporting a larger amount of densified product per given volume (as compared with a conventional non-densified product), additional benefits are provided in terms of reducing the number of transportation vehicles (trucks, trains, etc.) needed to carry a given volume of cereal, thus reducing fuel costs by minimizing fuel usage, which in turn, has desirable long-term environmental benefits, as noted above. Also, the capital and labor costs of such transportation can be reduced. Indeed, the reduction in distribution costs can exceed the saving from reductions in the amount of packaging required.

It is to be appreciated that while the reductions in packaging obtained herein may appear to be small (e.g., about 10%), the significance of such reductions cannot be overstated. Hundreds of millions of such packages are produced annually for RTE cereal products alone. Collectively, the savings in distribution and packaging alone are enormous. This does not even include the savings and benefits realized in the products' entire life cycle including reductions in the cost of trash collection and disposal.

FIGS. 4 through 9 show other exemplary container configurations. For example, FIG. 4 shows an alternative six-sided container 40 which is more cubular in shape as compared to conventional RTE cereal cartons. Such containers 40 have a generally lower aspect ratio of width to depth, such as about 1:1. FIG. 5 shows a container 50 which comprises a rigid carton 51 having four sides (front, back and each side) surrounded by flexible film 52, having a seam 53 on all four sides. FIG. 6 shows a container 60 having rounded corners 61. In one embodiment, as shown in FIG. 7, the container 70 has angled corners 71, such as the 45-degree angled corners. FIG. 8 is exemplary of a carton 80 having a gable top 81, similar to a milk carton, in another embodiment of the present invention.

The present invention is particularly beneficial for the packaging of regular or “non-pre-sweetened” cereals. Such non-pre-sweetened cereals typically are characterized by lower bulk densities as compared to pre-sweetened or sweetener-coated cereal products. For example, a puffed oat regular cereal can have a loose bulk density of about 0.08 g/cc. When pre-sweetened with a sugar coating, the loose bulk density of that puffed oat cereal can be up to 50% greater, such as 0.15 g/cc-0.16 g/cc. Such lower bulk density products require high container volumes for even modest quantities or weight amounts of RTE cereal. Reductions in the amount of packaging and reduction in shipping costs for such high volume, low weight products is particularly desirable.

FIG. 9 shows another embodiment comprising a substantially round container 90 similar to known oatmeal containers. In one embodiment, the container 90 has a lid 91, such as a pop-in lid as shown in FIG. 9. In one embodiment, the container 90 is constructed as a five-sided container. In one embodiment, the lid 91 is hinged. Again, for a similar aspect ratio in width:depth (or for a similar circumference in a substantially cylindrical container, such as the container shown in FIG. 9), the novel containers described herein (FIGS. 1-9), have a reduced height, or diameter, or both, resulting in a reduced overall volume, as compared to conventional containers.

Methods for Producing Densified Particulate Products

The novel packaging methods described herein provide a process for densifying a quantity of densifiable products by vibrating a bottom of a package formed around a mandrel and further vibrating the mandrel as it is being removed from the newly formed package. As such, the “action” in the novel process is all relative to the newly formed package. Additionally, the novel packaging methods are more efficient than conventional DP methods, with speeds comparable to or exceeding current bag-in-a-box packaging methods. In embodiments which utilize dual packages (e.g., flexible bag and carton), there is no need to allow for additional functional void or adjust content volume to avoid bulging of the carton, as with current bag-in-a-box methods. Of note, is that the intentional mechanical desnsification is practiced before the final closure seal is applied to the bag.

Embodiments of the present invention further provide a method for producing densified products, comprising densifying a quantity of densifiable particulate products such as densifiable particulate food products (hereinafter “densifiable food products”) during and/or after a filling process, but before the application of the final closure seal, wherein the filling process comprises transferring the densifiable food products from a temporary container to a sealable container, and the quantity of densifiable food products are densified prior to forming a closing seal in the sealable container. In one embodiment, the quantity of densifiable food products is one or more different types, shapes and/or sizes of densifiable food products. In variations, all or a part of the densification is practiced before the filling step or during the filling step.

In one embodiment, the process includes a densification step comprised of applying a vibrational force in one or more locations, of sufficient amplitude, frequency and duration to cause the densifiable food products to become densified. It is not contemplated that such a process includes any type of vacuum packing, although it may be possible to separately include a vacuum step, if desired. Also, both imperforate and vented sealed packages and pouches are contemplated herein.

Furthermore, the densification process is preferably practiced in a manner that minimizes product breakage. Of note, is that the novel densification methods discussed herein do not achieve volume reduction by compression. Furthermore, the various embodiments discussed herein do not contemplate increases in bulk density by mere blending with high density inclusions (although the present products can comprise added high density inclusions, e.g., raisins). In a preferred form, vibration is applied to the product from at least two directions or vectors (e.g., up-and-down and from the bottom and side-to-side).

FIG. 10A shows a simplified schematic of one embodiment of a densification system 100 for densifying densifiable products, such as densifiable food products. In the embodiment shown in FIG. 10A, the system 100 includes a cam track 105 along which mandrels 112 are moved and vibrated. Lower and upper chains, 102 and 104, respectively, provide horizontal rotating motion to the mandrel support 195. Each mandrel 112 is located on a mandrel support 195, which is attached to and moves along the lower and upper chains, 102 and 104, respectively. Any suitable number of chains or other similar components, such as pulleys, may be used.

One or more motors (not shown) turn one or more first shafts 106 at predetermined speeds. A pair of upper chain guides 101 and a pair of lower chain guides 103 (which rotate around the one or more first shafts 106) are adapted to guide the upper and lower chains, 104 and 102, respectively, during the densification process. Offset bearings (not shown) are mounted to one or more second shafts (not shown) and linked mechanically to the cam track 105. As the one or more second shafts turn, the offset bearings impart a reciprocating motion to the cam track 105.

A variety of supports, such as any type of vertical and/or horizontal supports may be used as needed. In the embodiment shown in FIG. 10A, horizontal support 107 provides support for a rail 110 used to tip the mandrels 112 into a substantially vertical position, while vertical supports 108A and 108B provide support to the cam track 105 via supports 109A and 109B, respectively, and further to the horizontal support 107.

Although not shown, such a system 100 necessarily includes a power source, as well as a wide variety of components, as is known in the art, and may further include a suitable computer system, for monitoring and controlling the system 100. The system 100 further includes any necessary linkages to vibrators, such as vibrators 198 shown in FIGS. 11A and 15.

During the densification process shown in FIGS. 10A, 11A, 15 and 18, each mandrel 112 is moved along the cam track 105 through various stations, such as the wrapping station 114 (which includes upper and lower film sources, 116 and 118, respectively), where film (250 and 252) (shown in FIG. 11B) is wrapped around an extension or lower portion 142 of the mandrel 112 and sealed longitudinally along its sides, a sealing station 117 (shown in FIG. 11A), where a first transverse seal is added to one end of the film to form a bag, a carton forming station 119, where a carton 121 (dispensed from a carton dispensing device 123 (which scores the cardstock to create folding lines and pre-applies hot melt adhesive for a manufacturer's joint, as is known in the art), is wrapped around the bag, and a filling station 115, where a quantity of particulate food products is added to the bucket or upper portion 140 of the mandrel 112 from a dispensing apparatus, such as the hopper 122 shown in FIG. 10A.

Prior to and/or during the time the mandrel 112 is passing through the filling station 115, the upper portion 140 and/or lower portion 142 may be vibrated intermittently or continuously. In one embodiment, the lower portion 142 is the portion which is primarily vibrated. In one embodiment, the lower portion 142 is vibrated continuously. The mandrel 112 is then tipped into a substantially vertical position as it engages the rail 110, causing the quantity of particulate food products 120 to fall, due primarily to gravitational forces, from the upper portion 140 of the mandrel 112 through to its lower portion 142. Prior to and/or during the time the mandrel 112 is being tipped into a substantially vertical position, the upper portion 140 and/or lower portion 142, may be vibrated intermittently or continuously to further densify the densifiable food products.

The mandrel 112 then continues around the cam track 105 until the upper portion 140 is removed (substantially vertically) from the newly formed densified packaged product (170) (location “F” in FIG. 15). Prior to and/or during the time the upper portion 140 of the mandrel 112 is being removed from the densified packaged product (170), the upper portion 140 and/or lower portion 142, may be vibrated intermittently or continuously. At this point in the process (location “F” in FIG. 15), the quantity of particulate food products 120 are densified, having a tapped bulk density at least about 10% greater than the original or loose bulk density (after being added to the upper portion 140 at the filling station 115).

The densified packaged product (170), having an open end, exits the cam track 105, and is sent to a second or final sealing station (not shown) where the final or closing seal to the bag is created. (See FIG. 17). Meanwhile, the mandrel 112 continues along the cam track 105 to begin the process anew.

As shown in the various figures, such as FIG. 10A, the cam track 105 is preferably non-circular to minimize the amount of floor space required in a manufacturing facility. In one embodiment, the cam track 105 has a substantially oval shape and includes a gradual incline along the back side, such that the cam track 105 is in a non-horizontal plane. The incline is provided to extract the mandrel 112. In one embodiment, the incline is about three (3) to five (5) degrees, although the invention is not so limited. Any suitable incline may be use in order to perform the desired process. After the densified packaged product (170) (See FIG. 15) exits the densification system 100, the mandrel 112 is lowered to start the process again.

The movement of the mandrel 112 in embodiments of the present invention is in contrast to conventional packaging methods in which a mandrel remains stationery during the filling process. In one embodiment, the densification process beginning at location “A” in FIG. 10A, continuing through locations “B”, “C” and “D” in FIG. 11A, through locations “E” and “F” in FIG. 15, through location “G” in FIG. 17 and through location “H” in FIG. 18. The time it takes one mandrel 112 to travel the entire circuit (essentially from location “A” to location “H”) is dependent on a number of factors, including package size (bag and/or carton). In one embodiment, it takes one mandrel 112 about 20 to 40 seconds, such as about 25 seconds, 30 seconds or 35 seconds, to travel from location “A” to location “H.” In another embodiment, it takes about 25 to 35 seconds for a single mandrel 112 to travel the entire circuit. In yet another embodiment, it takes about 28 to 32 seconds.

For even higher rates of production, multiple mandrel-filling sub-assemblies (not-shown) can be mounted on the cam track 105. In one embodiment, about 120 to 140 densified packaged products per minute are produced. In other embodiments, higher rates may be achieved, such as more than 140, up to 150, 160, 170 or even 180 densified packaged products produced per minute.

In the embodiment shown in FIG. 10A, the mandrel 112 is in a substantially horizontal position in location “A” just prior to the wrapping station 114. Essentially, the mandrel 112 is used to not only temporarily contain a quantity of particulate food products 120 (in the upper portion 140), but also as a package filling and forming device (in the lower portion 142). In practice, multiple mandrels 112 are moved along the cam track 105 at one time. In one embodiment, about 40 to 50 mandrels 112 are positioned at various locations along the cam track 105 at a given time. In a particular embodiment, about 47 to 49 mandrels, such as 48 mandrels 112 are simultaneously in motion along the cam track 105.

The mandrel 112 itself, shown in more detail in FIG. 10B, includes the bucket or upper portion 140 having a closed end 149, which includes two opposed side faces or inner side surfaces 144, an adjacent end face or inner end surface 146 and a bottom surface 141A into which densifiable food products may be added or poured. The mandrel 112 further includes an extension or lower portion 142 which is a hollow core having a bottom surface 141B having bottom edges 147 configured to form a discharge end 148. Packaging material (not shown) is wrapped around the lower portion 142 to form a bag.

In most embodiments, the upper portion 140 and lower portion 142 are contiguous, although the invention is not so limited. During the densification process, densifiable food products (not shown in FIG. 10B) added to the upper portion 140 flow through the upper portion 140 and into the lower portion 142 when the mandrel 112 is tipped substantially vertically from a substantially horizontal position. In one embodiment, the mandrel 112 is comparable to the mandrel described in U.S. Pat. No. 5,102,386 to the current assignee, which is hereby incorporated by reference in its entirety.

In one embodiment, the mandrel 112 has an interior surface designed to increase product drag or friction during product filling flow, thus causing the added particulates to pass through slower, thus improving densification (i.e., increasing the tapped bulk density) and reducing breakage. In one embodiment, the high drag surface of the mandrel 112, in combination with added vibration, maximizes void volume reduction, thus increasing densification of the particles.

In one embodiment, the surface of the mandrel 112 further includes internal protrusions or “speed bumps”, such as the dowel-shaped protrusions 143 shown in FIG. 10B, although the invention is not so limited. Protrusions and/or other means of increasing drag, may be useful during the densification step, as discussed herein, to assist in allowing the quantity of particulates to be re-oriented, such that voids are removed. In other words, the protrusions 143 or other surface irregularities help to fully settle the quantity of particulates within the mandrel 112 during vibration. A variety of protrusion shapes and sizes are possible within the mandrel 112. Conveniently, round or cylindrical dowels or ½ round dowels can be used.

In the embodiment shown in FIG. 10B, the protrusions 143 comprise a series of pegs on either side of the lower portion 142 of the mandrel 112. In this embodiment, the protrusions 143 have a length of between about 10% to about 50% of the width of the mandrel 112 and are alternated on either side of the mandrel 112 along its length. In another embodiment, the protrusions are any type of baffle or rib, including any type of curved or saddle shaped object. In one embodiment, any number of protrusions, such as up to three (3) protrusions having a substantially semi-circular shape, extend across the width of the mandrel 112 (See FIG. 21 and Example 1).

Referring now to FIG. 11A, at this point in the process, the mandrel 112 in location “B” has just entered the wrapping station 114 comprising the upper film source 116 and the lower film source 118 at which an upper film 250 and a lower film 252 are wrapped around a portion of the mandrel 112. In the embodiment shown in FIG. 11A, the upper film source 116 comprises a large roll of the upper flexible packaging film 250 on an upper film supply roller 260. Similarly, the lower film source 118 comprises a large roll of the lower film 252 on a lower film supply roller 264. The supply rollers (260 and 264) are motorized, sized, positioned and secured to allow film (250 and 252) to be dispensed at the desired amount and rate during the operation, as is known in the art.

Any number of film feed or tracking rollers may also be used to guide the film and ensure the film follows the desired path. In the embodiment shown in FIG. 11A, the upper film 250 is dispensed over first and second upper tracking rollers, 265 and 266, respectively, and then over a third upper tracking roller 268. Similarly, the lower film 252 is dispensed over first and second lower tracking rollers, 272 and 274, respectively, and then over a third tracking roller 276.

As the upper film 250 and lower film 252 exit the wrapping station 114, they are both fed through a sealer 254 having sealing jaws 155, which cut and seal the films (250 and 252) to form side seams (223) (see FIG. 11B) on either side of the mandrel 112. The sealer 254 further comprises a vacuum and or clamping bar 255 for holding the films (250 and 252) in place when no mandrel 112 is present.

FIG. 11B shows one embodiment of the mandrel 112 after having passed through the wrapping station 114 (FIG. 11A). In this embodiment, the lower portion 142 of the mandrel 112 has been wrapped in upper and lower films 250 and 252, respectively (and sealed longitudinally with one or more seals along its sides with the sealer 254 (FIG. 11A) to form the side seams 223.

Referring again to FIG. 11A, the mandrel 112, now wrapped around its lower portion 142 with the sealed films 250 and 252, then passes through the sealing station 117 where the first transverse seal (not shown) is added to one end of the sealed films (250 and 252) to form a bag, as discussed above.

In one embodiment, the bag is the only packaging or container for the densifiable food products 120. In the embodiments shown in FIGS. 10A, 11A, 15, 17 and 18, however, the novel densified packaged product is a single bag or barrier wrap enclosed within a carton 121, which itself is formed around the mandrel 112 (See, for example, location “C” in FIG. 11A).

The films (250 and 252) may be comprised of any suitable material as defined herein, and are not necessarily made from the same material. In embodiments in which the film(s) become the outer packaging, it may be a metalized film as is known in the art. The films (250 and 252) may further contain printing.

In an alternative embodiment shown in FIG. 12, only a single film source 312 is used. In this embodiment, the mandrel 112 is wrapped on four sides with the film cut and sealed along one edge.

Referring again to FIG. 11A, the mandrel 112 in location “C” has already passed through the sealing station 117 where a transverse seal (not shown) is formed in the film by a sealer 284 to produce a bag 286 having an opening on one end. In one embodiment, the transverse closure seal is formed along what will become the top of the densified packaged product (170). In another embodiment, the transverse seal is along what will become the bottom of the densified packaged product (170). In yet another embodiment, the transverse seal is made after passing through location “C.”

In one embodiment, the sealer 284 is a walking beam sealer, as is known in the art. In one embodiment, the sealer 284 is a continuous sealer with a continuous band. With a continuous sealer, individual jaws advance with a given package and then return to a starting location before following the next package, as is known in the art.

The mandrel 112 in location “C” has already passed through the filling station 115 where a quantity of particulate food products 120, such as a RTE cereal product, is added to the upper portion 140 of the mandrel 112 from the hopper 122. In one embodiment, the hopper 122 has a discharge end 5 which is sized to be compatible with the size of the mandrel 112. In one embodiment, a mechanical protrusion or “finger’ extends into the pouch or bag to expand it, prior to the time it is filled.

The hopper 122 may be a timing hopper, calibrated to dispense a known amount of particulates periodically, such as about every 0.1 to ten (10) seconds or 0.2 to one (1) seconds, such as about every 0.5 seconds. In one embodiment, the hopper 122 dispenses about nine (9) ounces at one time. In one embodiment, 8.9 ounces are dispensed. In one embodiment, 150 in³ of product is dispensed at one time.

The amount of product added at one time may affect the initial bulk density of the product. FIG. 13 provides a close up view of the filling station 115. The dispensing rate of the quantity of particulate food products 120 from the hopper 122, as well as the distance 6 from the discharge end 5 of the hopper 122 to the bottom surface 141A of the upper portion 140 of the mandrel 112, also affects the initial bulk density of the quantity of particulate food products 120. In one embodiment, the quantity of particulate food products 120 is approximately 8.9 oz (252.3 g), and is added to the mandrel 112 in one (1) to five (5) seconds, such as about two (2) seconds.

The hopper 122 may be located any suitable distance 6 from the bottom surface 141A of the upper portion of the mandrel 112 as shown in FIG. 13. In one embodiment, distance 6 is between about three (3) and 12 in, such as about five (5) to seven (7) in. The distance is dependent on a number of factors, such as package size, particulate type, and so forth. Generally, distance 6 is optimized to minimize breakage of the particulate food products 120 as they are released from the hopper 122, but also to allow travel of the mandrel 112 underneath the hopper 112 and/or to clear travel below the hopper 122.

Referring again to FIG. 11A, the mandrel 112 in location “C” is entering the carton forming station 119, where a carton 121 is provided from a carton dispenser 123 and formed around the bag 286 with a carton forming device 125 to create a novel densified packaged product. In the embodiment shown in FIG. 11A, the carton 121 is dispensed upside down, although the invention is not so limited. As such, the seal formed in the sealing station 117 is a “top” seal, as viewed by the consumer in the final product. In other embodiments, only a single packaging material is formed around the mandrel 112 to produce packages such as those shown in FIGS. 1-3 or any type of rigid packaging, such as an unlined or coated carton.

The mandrel 112 shown in location “D” in FIG. 11A has already passed through the filling station 115 and has been partially tipped up by the rail 110, causing the quantity of particulate food products 120 to pour into the bag 286, which itself is now surrounded by the carton 121. In this way, the quantity of particulate food products 120 is transferred from a temporary container (upper part of mandrel 140) to a shipping container (bag 286 and, optionally, additional the carton 121, formed around the mandrel 112).

The mandrels 112 are vibrated periodically throughout the process. In one embodiment, the mandrel 112 is subjected to vibration in one or more directions. In one embodiment, the mandrel 112 is subjected to a vibration in two-directions, such as vertically and horizontally, at a sufficient amplitude, frequency and duration to cause the quantity of particulate products to become densified. In one embodiment, the mandrel 112 is subjected to a vibration in only the vertical direction. In one embodiment, the vibration is an oscillating vibration. In other embodiments, any combination of vibrational directions may be used.

Vibration can occur at one or more locations as the mandrel 112 travels along the cam track 105. In one embodiment, the cam track 105 is vibrated using a vibrator 198 as is known in the art. In some embodiments, vibration is provided to the cam track 105 continuously or intermittently. In some embodiments, vibration is provided to each individual mandrel 112 at specific points in the process, such as, but not limited to, prior to or during the filling step and/or prior to or during some or all of the tilting step and/or during the time the mandrel 112 travels along the back portion of the cam track 105, and/or during the time the mandrel 112 is being extracted from the newly formed densified packaged product 170 (See FIGS. 16 and 17). In one embodiment, the vibration begins at location “C” or “D” and continues throughout the process or intermittently, as desired. In one embodiment, most of the vibration is applied directly to the upper portion 140 of the mandrel 112 for a portion or all of the time the mandrel 112 is being extracted from the newly formed densified packaged product 170, i.e., when the mandrel 112 is in location “F” (See FIG. 16). In such an embodiment, another mode of vibration may also be applied directly to the lower portion 142 of the mandrel 112 at any point in the process.

In one embodiment, the vibration is at a frequency of about five (5) to 50 Hz, or about 15 to 21 Hz or about 17 to 19 Hz, such as at about 17.5 to 18.5 Hz. In other embodiments, the frequency may be higher or lower, depending on a number of factors, including the type of densifiable food products being densified. If the frequency is too high, undesirable breakage of the particles may occur. If the frequency is too low, densification may be incomplete or may take too long for a given process.

In one embodiment, the mandrel 112 is vibrated for a total duration of less than 15 seconds, such as about 10 seconds or less, including any range there between, e.g., 1 to 15 seconds or 5 to 15 seconds or 10 to 15 seconds. In one embodiment, the vibration occurs for 15 seconds or more, up to 20, 30, 40, 50 or 60 seconds, including any range there between. Similarly, the amplitude may vary depending on a number of factors. In one embodiment, the amplitude is 0.1 to 0.5 cm, such as about 0.3 cm.

The timing of the vibration may also vary, depending on a number of factors, again, including the type of food product being densified. In one embodiment, vibration of the mandrel 112 begins prior to the filling station 115. In one embodiment, vibration of the mandrel 112 does not begin until after the mandrel 112 is filled with the quantity of particulate food products 120. In one embodiment, vibration does not begin until at least after the upper portion 140 of the mandrel 112 is partially or completely tipped vertically, causing the quantity of particulate food products 120 to flow into the lower portion 142. In one embodiment, vibration does not begin until the mandrel 112 is being removed from the densified packaged product (170).

Vibration of the mandrel 112 while still present within the newly formed container 168, now filled with particles, allows the load to be taken off the container, at least momentarily, thus maximizing the densification which can be achieved. Such a configuration prevents providing vibration to what may otherwise essentially become a “brick” of particles, which would only cause breakage. Again, the type of vibration utilized is dependent on the particle type. RTE cereal flakes, for example, are considered highly dense products, and thus may not require as much vibrating of the mandrel 112 while it is still inside the container 168.

Vibration may be provided by any suitable vibrator 198 connected via any suitable linkage to each mandrel 112. In one embodiment, the mandrel 112 is vibrated using any suitable type of device, such as an AC motor driving an offset bearing, mounted to a line shaft, and mechanically linked (not shown) to the cam track 105, which is capable of vibrating cam track 105 (and, in turn, the mandrel 112 and/or the densified packaged product (170) in FIG. 15) sufficiently to cause densification of the densifiable food product 120 contained therein.

In one embodiment, the mandrel 112 is vibrated vertically for about seven (7) to 15 seconds or six (6) to eight (8) seconds, such as about seven (7) seconds at a frequency of about 15 to 20 Hz or about 17 to 19 Hz, such as about 18 Hz, as it is being extracted from the nearly densified packaged product (170) (See FIG. 15). In one embodiment, the resulting product is fully densified after this step. In one embodiment, the densified packaged product (170) is further vibrated for several seconds, such as about two (2) to eight (8) seconds or about three (3) to five (5) seconds, such as about four (4) seconds, after the mandrel 112 is removed, in order to cause further densification to the densifiable food product 120 contained therein. In one embodiment, vibration continues until the final seal is formed in. In another embodiment, vibration is applied additionally or alternatively to the cam track 105 starting after the food products have been dispensed from the hopper 122. In one embodiment, vibration is applied primarily to the cam track 105. FIG. 14 shows one embodiment of a back surface 151 of a mandrel 112 as it travels along the cam track 105. In this embodiment, two cam followers 152, attached to a plate 154, are shown, although the invention is not so limited.

FIG. 15 shows the mandrel positioned at sequential points in time, i.e., in locations “E” and “F”, following the locations in FIG. 11A. In one embodiment, vibration occurs primarily as the mandrel 112 is being removed or extracted from the package, as shown in location “F”. Surface interaction between the mandrel 112 and the particles 122 during the extraction of the mandrel 112 momentarily lifts the particles 122, aiding in their densification.

FIG. 16 is a simplified schematic diagram showing an end view of the mandrel shown in FIG. 15 at location “D.” In this view, a curved component 161 made of a suitable material may be seen, which further helps to guide the container 113 as it is being tipped up. In one embodiment, the quantity of particulate food products 120 moves a very short distance over a roughened surface which results in the minimization of void spacing in the densified packaged product. As the mandrel 112, having a densified product in contact with the interior surfaces 141B of the lower portion142, is pulled away,

FIG. 17 shows the mandrel positioned at a sequential point in time, i.e., in location “G”, following the locations in FIG. 15, as discussed herein. FIG. 18 shows the mandrel at a sequential point in time, i.e., in location “H”, following the location shown in FIG. 17, as discussed herein.

Embodiments of the invention further comprise methods for making a densified packaged food product. In one embodiment, as shown in FIG. 19, the method comprises a process comprising wrapping 1902 a film around a mandrel; forming 1904 at least one transverse seam in the film to form a tube; sealing 1906 the tube on at least one end to form a bag; filling 1908 the bag with a quantity of densifiable particulate products having an initial bulk density between 0.08 and 0.3 g/cc; and vibrating 1910 the mandrel to produce a quantity of particulate products having a final bulk density at least 10% greater than the initial bulk density of the quantity of particulate products.

In one embodiment, a carton is also wrapped around the bag. In one embodiment, the step of vibrating 1910 involves vibrating the cam track along which the mandrel travels during the densification process, either intermittently or continuously. In one embodiment, the step of vibrating additionally comprises vibrating the lower portion of the mandrel and/or the container holding the quantity of densifiable particulate products and surrounding a portion of the mandrel. In one embodiment, the step of vibrating 1910 includes primarily vibrating the container. In one embodiment, about 60 to 80% of the vibration applied in this process is applied to the bottom of the container. In one embodiment, only the bottom of the container is vibrated.

In one embodiment, as shown in FIG. 20, the method comprises A process comprising densifying a quantity of densifiable particulate products, wherein the densifying comprises transferring 2002 the densifiable particulate products from a temporary container to a sealable container formed around a portion of the temporary container; and vibrating 2004 the temporary container, the sealable container or a combination thereof, wherein the quantity of densifiable particulate products are densified prior to forming a closing seal in the sealable container.

In one embodiment, the method comprises providing an elongated bucket having a U-shaped containing portion for holding a quantity of product at one end, the quantity of product in the form of particulates. In one embodiment, the U-shaped containing portion has a bottom surface and two opposed side faces, and an open face for receiving the quantity of particulates. In this embodiment the U-shaped containing portion has a closed first end, and an enclosed mandrel portion at its other end, with the mandrel portion having an open second discharge end and an interior passageway between and operatively connecting the open discharge end to the containing portion. In one embodiment, the interior passageway has an interior surface provided with a plurality of surface structures to provide flow resistance to particulate flow.

In one embodiment, the method further includes forming a bag around the mandrel portion of the elongated bucket by arranging a packaging film around the mandrel portion and forming one or more longitudinally extending side seals, such as a first longitudinally extending side seal and an opposed second side seal. In this embodiment, the method further includes forming a third transverse seal to create a bag having an open end with the mandrel portion disposed within, wherein the open end of the mandrel is proximate to the bottom of the bag. In one embodiment, the method further includes forming a carton around the bag.

Embodiments will be further described by reference to the following example, which is offered to further illustrate various embodiments. It should be understood, however, that many variations and modifications may be made while remaining within the scope of the embodiments described herein.

Example 1 Starting Materials and Equipment Ingredients

Honey Nut Cheerios®, Cinnamon Toast Crunch®, Wheaties®, Corn Chex®, Rice Krispies® and Kix® brand RTE cereals, Chex Mix® and Old Dutch Popcorn® snack products, and Betty Crocker® (BC) brand Hamburger Helper (HH) Fettuccini were shipped directly from various Generals Mills plants and distribution centers, to the James Ford Bell Technical Center laboratories of the Big G Cereal Division of General Mills, Inc. in Minneapolis, Minn., for use in Research and Development.

Kellogg's Sunshine® brand Cheez-it Crackers®, Frosted Flakes®, and Apple Jacks® products, as well as Old Dutch® Popcorn snack products and Lays® brand potato chips were purchased from a local retail outlet.

Equipment

Tests were run to determine bulk density changes for a variety of particulate food products after undergoing a densification process. Referring again to FIG. 21, a test stand 210 was constructed to perform the densification process. The test stand 210 includes a mandrel 213 insertable into a container 212. The mandrel 213 was made from stainless steel and was approximately 7.44 in (18.89 cm) wide, about 1.81 in (4.60 cm) depth and about 36 in (91.4 cm) in length, such that the total volume was approximately 7942 cc or 7.94 L. The container 212 was made with a Lexan® panel (for viewing product movement) and had various volumes, as indicated below in Table 1.

The mandrel 213 included three (3) wooden dowels 214, about 7.375 in (18.73 cm) in length and 0.375 in (0.95 cm) in diameter located on a back inner side of the mandrel 213 as shown in FIG. 21. The dowels 214 served as protrusions or bumper stops for the particulate food products being added as discussed above (momentarily lifting the test samples as the mandrel 213 was being removed from the container 212. In this way, a reduced amount of the particulates in the test product were subjected to the bottom vibration.

The test stand was vibrated using vibrators, a mandrel vibrator 216A and a container vibrator 216B (hereinafter “vibrators 216A and 216B”), which were custom-made servo motor driven systems. Linkages (not shown) were used to raise the mandrel 213 in 0.125 in (0.32 cm) increments. The vibrators 216A and 216B were each programmed to cycle at 18 cycles per second. The rapid starting and stopping of the vibrators 216A and 216B (i.e., servo motors) imparted the vertical vibration to the mandrel 213 and the container 212.

An electronic Ohaus Ranger J0652 scale was used to weigh test samples.

Two custom-made volume cylinders (having volumes of 2819 cc and 5834 cc) made from Lexan® and aluminum, were used to initially hold test samples.

A custom made screen was used to separate out any breakage. The screen was a 2 ft (61 cm) square screen having openings approximately 0.375 in (0.95 cm) in diameter.

Test Procedure

An initial density of each test sample was determined as follows:

1. Taring a cylinder to “0” weight on a conventional laboratory scale (i.e., accounting for the cylinder weight);

2. Pouring a desired amount of product into a receiving funnel located on top of the cylinder;

3. Releasing a custom-made sheet metal gate between the funnel and the cylinder to allow product to fall into the cylinder without any vibration

4. Reinserting the sheet metal gate and pouring out excess product from the funnel;

5. Placing cylinder on the scale to determine the mass of the product therein; and

6. Calculating and recording the initial density as shown in Table 1 below.

Each mandrel 213 was lowered into the container 212. A predetermined target weight of each food product was then pre-weighed on the scale (i.e., product was added until the predetermined target weight was reached, as measured by the scale) and then poured into the container 212 as described below. (See Table 1 for details as to individual test samples).

A “package fill percentage” was determined by pouring product in a substantially uniform manner over a period of approximately two (2) seconds, into a custom-made Lexan® package fill measuring container (not shown) (hereinafter “measuring container.”)

A theoretical maximum densification test was then performed as follows:

1. The predetermined target weight of each product was poured into the container 212 over a 30 second time period. The vibrators 216A and 216B were run for the 30 second filling time, and continued to run for another 60 seconds to eliminate any remaining void spaces between the food particulates located in the container 212.

2. The package fill level for each test product was determined by measuring from the top of the resulting product bed to a score line 220 shown in FIG. 21; and

3. The change in height of the product bed due to densification was then calculated (package fill from cylinder and package fill after densification as measured in the container 212=% change due to densification).

A “7 sec mandrel vibration/11 sec container vibration” densification test was then performed, i.e., (wherein the selected product is vibrated for seven (7) seconds by both the mandrel and container, while the mandrel 213 is being lifted out of the container 212, with vibration continuing for an additional four (4) seconds on the container 212. This test involved lowering the mandrel 213 into the container 212 and then uniformly pouring the selected product into the container 212 over a two (2) second time period.

The vibrators 216A and 216B were then turned on and operated for approximately seven (7) seconds, during which time the mandrel 213 was slowly lifted from the container 212, while both the container 212 and mandrel 213 vibrated. The rate of speed for the upwardly movement of the mandrel 213 was determined by measuring the speed at which a mandrel was removed from a container on production equipment, and then programming the vibrators 216A and 216B (servo motors) to reproduce this same movement on the test machine. As a result, the distance the mandrel 213 traveled was 33.02 cm (13 in) for complete removal from the container 212.

Vibrator 216B (the container vibrator) continued to run for another four (4) seconds after the mandrel 213 was removed to allow for additional vibration of the test products in the container 212. After a series of experiments were conducted, it was determined that optimal results were achieved with each vibrator 216A and 216B operating at a frequency of approximately 18 Hz and an amplitude of about 0.3 cm.

Thereafter, product height in the container 212 was measured from the top of the product being tested to the score line 220. A change in height due to densification was calculated (package fill from cylinder and package fill after densification as measured in the carton=% change due to densification).

The experimental process was repeated with changing inputs for vibration, frequency and amplitude, until results were within two (2) % of the theoretical maximum densification test.

Thereafter, breakage and fines were removed (i.e., scalped) from the product in the cylinder by pouring the entire contents of the cylinder onto the screen and moving the screen back and forth manually about one (1) in (2.54 cm) in either direction for a period of about one (1) minute.

If the collected fines and small particles weighed at least five (5) grams, the % of fines and small particles were calculated. The measured amount was an indicator as to whether or not the densification process imparted any significant breakage into the product.

Results

The reported initial and final bulk densities are averages from 12 test runs for each type of food product using the optimal settings of frequency and amplitude noted above. The results of the testing are summarized in Table 1 below:

TABLE 1 Test Results Initial (Loose) Bulk Product Density Bulk Package Fill % (“Average” Container Size Product Density Density Final (Packed) Density Density Starting Ending Package Fill Dowels values) (in³) (cc) Mass (g) (g/in³) (g/cc) (g/in³) (g/cc) Δ (%) (%) (%) Reduction (%) (no.) HH ® Fettuccine 172 2819 1056 5.35 0.33 6.42 0.39 20% 100 83 17% 0 Chex ® Mix 172 2819 669 3.63 0.22 4.04 0.25 11% 100 90 10% 3 Old Dutch ® 172 2819 100 0.58 0.034 0.64 0.04 10% 100 91  9% 3 Popcorn Cheez-it ® 172 2819 665 3.58 0.22 4.05 0.25 13% 100 89 11% 0 Crackers Lays ® 172 2819 199 1.05 0.06 1.35 0.08 28% 100 78 22% 0 Potato Chips Frosted Flakes ® 172 2819 456 2.6 0.16 3.2 0.2 24% 100 81 19% 0 Apple Jacks ® 172 2819 326 1.73 0.11 1.92 0.12 11% 100 90 10% 0 Rice Krispies ® 172 2819 307 1.67 0.1 1.87 0.11 12% 100 89 11% 0 BC ® Hash Browns 172 2819 921 5.02 0.31 6.39 0.39 27% 100 79 21% 0 Yellow Box 172 2819 305 1.65 0.1 1.85 0.11 12% 100 89 11% 0 Cheerios ® Wheaties ® 172 2819 404 2.16 0.132 2.57 0.157 19% 100 84 16% 3 Cinnamon 172 2819 465 2.55 0.156 2.97 0.181 16% 100 86 14% 0 Toast Crunch ® Honey Nut 172 2819 417 2.39 0.146 2.67 0.163 12% 100 89 11% 0 Cheerios ® KIX ® 172 2819 291 1.61 0.098 1.80 0.110 12% 100 90 10% 0 Lucky Charms ® 172 2819 395 2.16 0.132 2.48 0.151 15% 100 87 13% 0 BC ® Scalloped 172 2819 458 2.52 0.154 3.10 0.189 23% 100 81 19% 0 Potatoes HH ® Asian 172 2819 1009 5.28 0.322 6.11 0.373 16% 100 87 13% 3 Style Beef

Conclusions

As Table 1 shows, reductions in bulk density are achievable for a wide variety of densifiable particulate products. Additionally, it was observed that there was no significant breakage of the food product (which was confirmed by the weights of the collected fines and small particles).

Example 2 Prophetic

Testing will be performed to determine the ratio of product weight to surface area for various particulate products densified according to the methods described herein, as compared to conventional packaged products. It is expected that the ratio will increase by at least 6%, such as at least 8, up to 10% or more, such as up to about 25%.

Conclusion

Any of the aforementioned commercial devices can include a system controller. The system controller can be coupled to various sensing devices to monitor certain variables or physical phenomena, process the variables, and output control signals to control devices to take necessary actions when the variable levels exceed or drop below selected or predetermined values. Such amounts are dependent on other variables, and may be varied as desired by using the input device of the controller. The non-volatile memory may comprise a disk drive or read only memory device which stores a program to implement the above control and store appropriate values for comparison with the process variables as is well known in the art. Such sensing devices may include, but are not limited to, devices for sensing temperatures, pressures and flow or dispensing rates, and transducing the same into proportional electrical signals for transmission to readout or control devices may be provided for in all of the principal fluid flow lines.

It will be understood by those skilled in the art that the apparatus for manufacturing the densified particulate products includes all known apparatus for moving components into, through and out of a food processing system. This includes, but is not limited to, various types of pumps, filters, strainers (such as magnetic strainers, decline dual strainers, etc.), flow meters, drains, level indicators, grate magnets, and so forth. (A grate magnet is essentially a series of parallel magnetic bars placed in an ingredient or product stream to remove magnetic metal particles from the stream as a consumer protection measure).

It will further be understood by those skilled in the art that all of the lines in the system are made from materials that can be either flexible or rigid, depending on their location and use. Furthermore, all lines are of a suitable diameter for their intended purpose, but are preferably between about (0.5 in) 1.3 cm and about four (4) in (ten (10) cm) in diameter. It will also be appreciated by those skilled in the art that flexible lines can include hoses made from rubber, plastic or other suitable material, and rigid lines can be made from galvanized metal, stainless steel, copper, PVC or other suitable material.

The various embodiments of the present invention provide multiple advantages, including, but not limited to, reduction of material required for containers, which not only reduces costs, but results in reduced product weight and size. The reduced size means less shelf space is required for the same amount of product. The reduced size means also fewer trucks are required to ship the same amount of product. The reduced weight, as well as the need for fewer trucks, not only results in a substantial savings in labor costs, but the resulting reduction in fuel consumption also helps the environment. The novel methods described herein further is expected to produce a product having an enhanced shelf life. Also, the invention herein provides additional environmental benefits in reduction of food packaging waste collection and disposal.

As noted above, the inventor is the first to recognize a significant need in the art for an improved particulate packaged product and methods of making same. In contrast to conventional methods, such as double packaging methods, in the embodiments described herein, the bag is filled with product while still wrapped around the mandrel. In contrast to the conventional bag-in-a-box method, the embodiments described herein provide a process in which product is added to the bag while it is still wrapped around the mandrel. In those embodiments in which a carton is added, the carton is also wrapped around the bag while the bag is still wrapped around the mandrel. The integrated novel process described herein, which includes vibration at one or more locations a sufficient frequency and amplitude and for a sufficient time, produces a packaged product which is densified prior to the formation of the closing seal on the bag.

All publications, patents and patent documents are incorporated by reference herein, each in their entirety, as though individually incorporated by reference. In the case of any inconsistencies, the present disclosure, including any definitions therein, will prevail.

Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown. For example, although the food products shown and described are either o-shaped or rectangular (e.g., square) RTE cereal products, any type and shape of densifiable RTE cereal product, as well as any type of densifiable snack product or dehydrated product, as defined herein, may be used. Additionally, although the densified packaged products and methods have been shown and described for densifiable food products, it is also possible to utilize the novel methods described herein with densifiable non-food products, such as pet foods, pharmaceuticals, and so forth.

Therefore, this application is intended to cover any adaptations or variations of the present subject matter. Therefore, it is manifestly intended that embodiments of this invention be limited only by the claims and the equivalents thereof. 

1. A packaged product comprising: a container having a container volume; and a quantity of densified particulate products having a tapped bulk density ranging from 0.08 g/cc to 0.4 g/cc disposed within the container, wherein the quantity of densified particulate products occupies more than 85% of the container volume.
 2. The packaged product of claim 1 wherein the quantity of densified particulate products occupies at least 90% of the container volume.
 3. The packaged product of claim 1 wherein a difference in an initial tapped bulk density upon fabrication and a final tapped bulk density after shipping is no more than five (5) %.
 4. The packaged product of claim 1 wherein the quantity of densified particulate products occupies at least 95% of the container volume.
 5. The packaged product of claim 1 wherein the container volume is reduced in size as compared to a conventional container volume having an identical quantity of non-densified packaged products disposed therein.
 6. The packaged product of claim 5 wherein the container volume is reduced in size by about 3.6% up to about 25%.
 7. The packaged product of claim 1 wherein the container is a sealed container having a first transverse seal with a lower edge.
 8. The packaged product of claim 7 wherein the quantity of densified particulate products form a bed having a top surface, and a distance between the lower edge of the first transverse seal and the top surface of the bed is no more than three (3) cm.
 9. The packaged product of claim 8 wherein the distance is no more than 1.25 cm.
 10. The packaged product of claim 1 wherein the container is a flexible bag.
 11. The packaged product of claim 10 wherein the flexible bag is made from polyethylene or polyester.
 12. The packaged product of claim 10 wherein the flexible bag is a stand-alone container which is wider at the bottom.
 13. The packaged product of claim 10 wherein the flexible bag is metalized.
 14. The packaged product of claim 10 further comprising a carton surrounding the flexible bag.
 15. The packaged product of claim 1 wherein the carton has a substantially rectangular shape.
 16. The packaged product of claim 1 wherein the carton has a substantially cubular shape.
 17. The packaged product of claim 1 wherein the carton has a substantially cylindrical shape.
 18. The packaged product of claim 1 wherein the carton has a gable top.
 19. The packaged product of claim 1 wherein the quantity of densified particulate products is a quantity of densified particulate food products.
 20. The packaged product of claim 19 wherein the quantity of densified particulate food products is frangible ready-to-eat (RTE) cereal pieces.
 21. The packaged product of claim 20 wherein the cereal pieces have shapes selected from o-rings, spheres, rectangles, squares and any combination thereof.
 22. The packaged product of claim 19 wherein the quantity of particulate food product is selected from uncooked pasta, dehydrated potatoes, and snack products, wherein the snack products include bugle-shaped products, loosely packed crackers, and potato chips.
 23. The packaged product of claim 1 wherein the container volume is about five (5) % to 25% smaller than a container volume for the same quantity of non-densified particulate products.
 24. The packaged product of claim 1 wherein the container has an aspect ratio of width to depth of about 3.5 to 1 and a height no more than about 20.3 cm.
 25. The packaged product of claim 1 wherein the quantity of particulate food products has a product weight and ratio of the product weight to the container volume is greater than 3.6% and less than 25%.
 26. The packaged product of claim 1 wherein the product weight is at least 252 grams. 